Mesh fabric and mesh fabric garment

ABSTRACT

A warp knitted mesh fabric constructed of synthetic, or synthetic and natural, fibers is characterized by having a low density, open construction with a high profile for spacing a garment constructed from the fabric from the skin of a wearer of the garment.

PRIORITY CLAIM

This utility patent application claims priority to the Provisional Application No. 63/167,159 filed on Mar. 29, 2021, the contents of which are incorporated by reference into this application.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates to an open, breathable fabric suitable for a wide range of uses and to garments fabricated in whole or in part from such fabrics.

Textile fabrics can be created in many forms—woven, non-woven, braided and knitted. Knitted fabric structures, which can be formed by warp knitting or weft knitting of varying types, are highly flexible, conformable and can be designed to have high porosity. In warp knitting, yarns follow a zigzag pattern along the long direction of the fabric, forming wales. These yarns are looped together to form courses. The properties and applications of the knitted textile structure can be tailored based on factors including the types of machines, structures, stitches, yarns and needle sizes used during the warp knitting process.

Tricot warp knitting enables production of fabrics having low density and a high profile. The warp yarns pass through one to four guide bars using shogging and swinging motions—typically electronically controlled through a Human-Machine Interface (HMI), or remotely networked through CAD knitting software. Servo motor-controlled warp beam let-off and fabric take-up systems provide precise tension control throughout the fabric formation process. Infinite pattern repeat functionality supports the design of highly engineered fabrics with regions of specialized physical and mechanical properties where desirable.

In the particular embodiment shown in this application by way of example, the fabric has a net-like mesh construction that has a thickness dimension that provides an air space between the skin of a wearer and, for example, an outer garment that overlies the fabric. One such specific application is for use as an undergarment worn beneath heavy, densely-fabricated clothing of the type worn by, for example, military, law enforcement, public safety and fire fighting personnel. The inventive fabric provides a “standoff” that allows air flow, heat dispersion and moisture evaporation between the undergarment and an outer garment. The fabric is lightweight and possesses several characteristics that make it particularly adapted for the uses described above, among others. These characteristics include no melt and no drip flame resistant performance, superior warmth resulting from a unique open construction that creates air pockets of insulation next to the skin, as well as anti-microbial, wicking and quick drying performance. The fabric is easily condensed into a small volume for packaging, shipment and storage.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a fabric that possesses characteristics including a net-like mesh construction that has a thickness dimension that provides an air space between the skin of a wearer and an outer garment.

It is another object of the invention to provide a fabric that is intended for use as an undergarment worn beneath heavy, densely-fabricated clothing of the type worn by, for example, military, law enforcement, public safety and fire fighting personnel.

It is another object of the invention to provide a fabric that includes no melt and no drip flame resistant performance, superior warmth resulting from a unique open construction that creates air pockets of insulation next to the skin, and that has anti-microbial, wicking and quick drying performance.

It is another object of the invention to provide a fabric that is easily condensed into a small volume for packaging, shipment and storage.

It is another object of the invention to provide garments according to various suitable designs that have the characteristics described and defined in this application.

These and other objects and advantages of the invention are achieved by providing a fabric that is warp knitted with a low density and a high profile.

According to one aspect of the invention, a knitted mesh fabric is provided and includes a plurality of longitudinally and transversely extending warp-knitted yarns constructed of synthetic, or synthetic and natural, fibers forming an open, planar framework, the open, planar framework including air transmission openings defined by a yarn/void ratio of between 40-55 percent; and the fabric further characterized by air permeability of at least 1000 Pa (0.15 Psi) between an underlying surface and an overlying surface in relation to the fabric.

According to another aspect of the fabric invention, the fabric is constructed of yarns formed of synthetic fibers.

According to another aspect of the fabric invention, the synthetic fibers are modacrylic fibers and rayon fibers.

According to another aspect of the fabric invention, the rayon fibers are flame retardant rayon fibers.

According to another aspect of the fabric invention, the fabric is constructed of yarns formed of about 78 percent modacrylic fibers and about 22 percent flame retardant rayon fibers.

According to another aspect of the fabric invention, the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric.

According to another aspect of the fabric invention, the fabric has an uncompressed thickness of between 0.0198 in. (0.5 mm) and 0.0242 in. (0.6 mm).

According to another aspect of the fabric invention, the fabric is constructed of yarns formed of synthetic fibers and natural fibers.

According to another aspect of the fabric invention, the synthetic fibers are rayon and nylon fibers and the natural fibers are wool fibers.

According to another aspect of the fabric invention, the rayon fibers are flame retardant rayon fibers.

According to another aspect of the fabric invention, the fabric is constructed of yarns formed of about 50 percent flame retardant rayon, about 30 percent wool and about 20 percent nylon fibers.

According to another aspect of the fabric invention, the warp knit fabric is a tricot warp knit fabric.

According to another aspect of the fabric invention, the fabric has stretch in the width (course) direction of between about 25 percent and 35 percent.

According to another aspect of the fabric invention, the fabric has a weight of between about 3.5 oz/yd² (118 g/m²) and about 4.3 oz/yd² (146 g/m²).

According to another aspect of the invention, a garment constructed of a knitted mesh fabric is provided, wherein the fabric is constructed of a plurality of longitudinally and transversely extending warp-knitted yarns constructed of synthetic, or synthetic and natural, fibers forming an open, planar framework. The open, planar framework includes air transmission openings defined by a yarn/void ratio of between 40-55 percent. The garment is further characterized by the fabric having an air permeability of at least 1000 Pa (0.15 Psi) between an underlying skin surface and an overlying surface in relation to the fabric.

According to another aspect of the garment invention, the garment is an undergarment selected from the group consisting of an upper body undergarment for a human, a lower body undergarment for a human and a full body garment for a human.

According to another aspect of the garment invention, the fabric is constructed of yarns formed of synthetic fibers.

According to another aspect of the garment invention, the synthetic fibers are modacrylic fibers and rayon fibers.

According to another aspect of the garment invention, the rayon fibers are flame retardant rayon fibers.

According to another aspect of the garment invention, the fabric is constructed of yarns formed of about 78 percent modacrylic fibers and about 22 percent flame retardant rayon fibers.

According to another aspect of the garment invention, the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric.

According to another aspect of the garment invention, the fabric has an uncompressed thickness of between 0.0198 in. (0.5 mm) and 0.0242 in (0.6 mm)

According to another aspect of the garment invention, the fabric is constructed of yarns formed of synthetic fibers and natural fibers.

According to another aspect of the garment invention, the synthetic fibers are rayon and nylon fibers and the natural fibers are wool fibers.

According to another aspect of the garment invention, wherein the rayon fibers are flame retardant rayon fibers.

According to another aspect of the garment invention, the fabric is constructed of yarns formed of about 50 percent flame retardant rayon, about 30 percent wool and about 20 percent nylon fibers.

According to another aspect of the garment invention, the warp knit fabric is a tricot warp knit fabric.

According to another aspect of the garment invention, the fabric has stretch in the width (course) direction of between about 25 percent and 35 percent.

According to another aspect of the garment invention, the fabric has a weight of between about 3.5 oz/yd² (118 g/m²) and about 4.3 oz/yd² (146 g/m²).

According to another aspect of the garment invention, the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric of the invention the fabric is a tricot warp knit fabric.

According to another aspect, of the garment invention the fabric is constructed of a combination of synthetic and natural fiber yarns.

According to another aspect of the garment invention, the fabric is constructed of synthetic fiber yarns.

According to another aspect of the garment invention, the fabric is constructed of modacrylic and rayon fiber yarns.

According to another aspect of the garment invention, the fabric is constructed of modacrylic, rayon and wool fiber yarns.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The present invention is best understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:

FIG. 1 is an environmental view of a fabric according to a preferred embodiment of the fabric, fabricated into undergarments suitable for use with military outer garments as worn by military personnel, as shown;

FIG. 2 is a plan view of an upper torso garment according to one embodiment of the invention;

FIG. 3 is a plan view of a lower torso garment according to one embodiment of the invention;

FIG. 4 is a plan view of a full torso garment according to one embodiment of the invention;

FIG. 5 is a plan view, to scale, of a fabric according to a preferred embodiment of the invention;

FIG. 6 is a microphotograph of the technical face of a fabric according to one embodiment of the invention showing the warp knit intersection of adjacent yarns;

FIG. 7 is a microphotograph of the technical face of a fabric according to one embodiment of the invention showing the mesh opening formed in the fabric;

FIG. 8 is a microphotograph of the technical back of a fabric according to one embodiment of the invention showing the warp knit intersection of adjacent yarns; and

FIG. 9 is a microphotograph of the technical back of a fabric according to one embodiment of the invention showing the mesh opening formed in the fabric.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

Referring now to the Figures, FIGS. 1, 2 and 3 are schematic views of a preferred embodiment of the fabric, fabricated into upper and lower undergarments 10 and 20, respectively, and suitable for use under military outer garments by military personnel “M”. As shown in other drawings and in the text below in further detail, the upper and lower undergarments 10 and 20 are fabricated of an open, mesh warp knit fabric 40 characterized by providing enhanced ventilation and other comfort and safety characteristics to the wearer, particularly when worn under heavy, densely knitted, woven or non-woven garments such as often worn by military, law enforcement, fire fighting, emergency and similar occupations.

FIG. 4 shows a single piece, upper and lower undergarment 30 fabricated of the same fabric 40.

Referring to FIG. 5, the exemplary fabric 40 is constructed of a plurality of longitudinally and transversely extending warp-knitted yarns constructed of synthetic, or synthetic and natural, fibers forming an open, planar framework, a segment of which is shown at reference numeral 42. As shown, the framework 42 defines diamond-shaped openings 44.

The combination of features of fabric 40, including the weight, number, size and shape of the openings 44 and thickness provide a high profile “standoff” between the skin of a wearer and an outer garment. This feature provides for enhanced air and moisture ventilation, allowing perspiration to evaporate more rapidly, and also provides at the same time a physical barrier between the skin and an outer garment, which may have a rough, abrasive inner surface texture.

The fabric 40 may be constructed of synthetic, or synthetic and natural, fiber yarns having the characteristics set out by way of example in Table A, below.

Fabrics within the scope of the invention may have differing characteristics from those as described in Table A, which is for purposes of example only. By reference to the ruler shown in FIG. 5, it will be observed that each square inch (6.5 cm) of the fabric 40 has approximately 12 openings formed by the warp knitting process. In this particular embodiment, the openings comprise approximately 40-55 percent of the surface area of the fabric, calculated by edge detection and area calculation.

TABLE A H3640 AM H3672 AM H3684 AM Sample Result Sample Result Sample Result Characteristic Test Method Dec. 14, 2020 Dec. 14, 2020 Dec. 14, 2020 Construction Tricot warp knit with Tricot warp Tricot warp antimicrobial & knit with knit with moisture antimicrobial antimicrobial & management & moisture moisture management management Fiber Identification 78% Modacrylic 78% 50% FR Rayon 22% FR Rayon- 28/1 Modacrylic 30% Wool Cotton Count; 21 Tex 22% FR Rayon- 20% Nylon- 28/1 Cotton 33/1 Worsted Count; 21 Tex Count- Y1 Tex Weight, oz. per sq. yard ASTM D3776 3.5 oz/yd² 4.0 oz/yd² 4.3 oz/yd² (Method C) 118 g/m² 136 g/m² 146 g/m² Thickness ASTM 0.021 0.022 0.024 (lnches)(Uncompressed) D1777-96 Width 52″; 1.3 m 60″; 1.5 m 60″; 1.5, Yarn Void Ratio Edge 51.3% 44.7% 44.5% Detection and Area Calculation Bursting Strength lbs ASTM D3787 55.8 60.2 57.8 (minimum) Colorfastness to AATCC-61, 5.0 5.0 4.5 Laundering Option 2a, 3 cycles, grade poly only Colorfastness to AATCC 8 Dry 4.5 Dry 4.5 Dry 5.0 Crocking Wet 4.0 Wet 5.0 Wet 3.5 Dimensional Stability AATCC 135, 3 Length: 3.22% Length: -4.40% Length: 19.9% cycles, (I), III, Width: 14.12% Width: -8.43% Width: 18.7% (A), ii Pilling ASTM D3512 5.0 5.0 4.0 Snag Test (courses and ASTM D3939 Courses: 45 Courses: 5.0 Courses: 4.5 wales) Wales: 4.5 Wales: 4.5 Wales: 4.5 Air Permeability ASTM D737 1000 + CFM 1000 + CFM 1000 + CFM (28 CMM) (28 CMM) (28 CM) Stretch, percent, ASTM D2594 25% 35% 25% Width(Course) only (Loose Fit) Fabric Growth, Course ASTM D2594 60 sec: 5% 60 sec: 5% 60 sec 5% only (Loose Fit) 1 hour: 5% 1 hour: 0% 1 hour 0% Water sorption and Procedure Pass Pass 3 sec/1″ wicking from Natick Pass & AATCC-135, 20 cycles, (1), III, (A), ii and 3.2.2 Vertical Flame- Initial ASTM D- 6413 Wales: After Flame 0 seconds 17 seconds After Glow 0 seconds 0 seconds Char 3.75″ 7.9″ Melt/Drip No Melt/No No Melt/No Drip Drip Courses: After Flame 0 seconds 42 seconds After Glow 0 seconds 0 seconds Char 3.33″ 9.73″ Melt/Drip No Melt/No No Melt/No Drip Drip Vertical Flame- After 5 ASTM D- Launderings 6413 & AATCC-135, 5 cycles (1), III, (A), ii Wales: After Flame 0 seconds 113 seconds After Glow 0 seconds 0 seconds Char 3.75″ 9.2″ Melt/Drip No Melt/No No Melt/No Drip Drip Courses: After Flame 0 seconds 90 seconds After Glow 0 seconds 0 seconds Char 4.2″ 9.29″ Melt/Drip No Melt/No No Melt/No Drip Drip

FIGS. 6, 7, 8, and 9 are microphotographs of the technical face (FIGS. 6 and 7) and back (FIGS. 8 and 9) of the fabric 40 according to one embodiment of the invention, showing the warp knit intersection of adjacent yarns and the mesh openings 44 formed in the fabric 40. The diamond-shape opening 44 is particularly well shown in FIG. 7.

Referring again to FIGS. 2, 3 and 4, the garments 10, 20 and 30 can be constructed using conventional cut-and-sew techniques. Overedge seaming, for example, can be used to construct the garments 10, 20 and 30 from lengths of the fabric 40, and fabrics of other yarns and specifications can be incorporated into garments constructed of fabrics according to the present invention.

A mesh fabric and garments constructed from such fabrics according to the invention has been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. 

We claim:
 1. A knitted mesh fabric, comprising: a. a plurality of longitudinally and transversely extending warp-knitted yarns constructed of synthetic, or synthetic and natural, fibers forming an open, planar framework; b. the open, planar framework including air transmission openings defined by a yarn/void ratio of between 40-55 percent; and c. the fabric further characterized by air permeability of at least 1000 CFI between an underlying surface and an overlying surface in relation to the fabric.
 2. The knitted mesh fabric according to claim 1, wherein the fabric is constructed of yarns formed of synthetic fibers.
 3. The knitted mesh fabric according to claim 2, wherein the synthetic fibers are modacrylic fibers and rayon fibers.
 4. The knitted mesh fabric according to claim 3, wherein the rayon fibers are flame retardant rayon fibers.
 5. The knitted mesh fabric according to claim 1, wherein the fabric is constructed of yarns formed of about 78 percent modacrylic fibers and about 22 percent flame retardant rayon fibers.
 6. The knitted mesh fabric according to claim 1, wherein the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric.
 7. The knitted mesh fabric according to claim 1, wherein the fabric has an uncompressed thickness of between 0.0198 in. (0.5 mm) and 0.0242 in. (0.6 mm).
 8. The knitted mesh fabric according to claim 1, wherein the fabric is constructed of yarns formed of synthetic fibers and natural fibers.
 9. The knitted mesh fabric according to claim 8, wherein the synthetic fibers are rayon and nylon fibers and the natural fibers are wool fibers.
 10. The knitted mesh fabric according to claim 9, wherein the rayon fibers are flame retardant rayon fibers.
 11. The knitted mesh fabric according to claim 10, wherein the fabric is constructed of yarns formed of about 50 percent flame retardant rayon, about 30 percent wool and about 20 percent nylon fibers.
 12. The knitted mesh fabric according to claim 1, wherein the warp knit fabric is a tricot warp knit fabric.
 13. The knitted mesh fabric according to claim 1, wherein the fabric has stretch in the width direction of between about 25 percent and 35 percent.
 14. The knitted mesh fabric according to claim 1, wherein the fabric has a weight of between about 3.5 oz/yd² (118 g/m²) and about 4.3 oz/yd² (146 g/m²).
 15. A garment constructed of a knitted mesh fabric, comprising: a. a plurality of longitudinally and transversely extending warp-knitted yarns constructed of synthetic, or synthetic and natural, fibers forming an open, planar framework; b. the open, planar framework including air transmission openings defined by a yarn/void ratio of between 40-55 percent; and c. the garment further characterized by the fabric having an air permeability of at least 1000 CFM between an underlying skin surface and an overlying surface in relation to the fabric.
 16. The garment according to claim 15, wherein the garment is an undergarment selected from the group consisting of an upper body undergarment for a human, a lower body undergarment for a human and a full body garment for a human.
 17. The garment according to claim 16, wherein the fabric is constructed of yarns formed of synthetic fibers.
 18. The garment according to claim 17, wherein the synthetic fibers are modacrylic fibers and rayon fibers.
 19. The garment according to claim 18, wherein the rayon fibers are flame retardant rayon fibers.
 20. The garment according to claim 15, wherein the fabric is constructed of yarns formed of about 78 percent modacrylic fibers and about 22 percent flame retardant rayon fibers.
 21. The garment according to claim 15, wherein the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric.
 22. The garment according to claim 15, wherein the fabric has an uncompressed thickness of between xxx in. (xxx mm) and xxx in. (xxx mm).
 23. The garment according to claim 15, wherein the fabric is constructed of yarns formed of synthetic fibers and natural fibers.
 24. The garment according to claim 23, wherein the synthetic fibers are rayon and nylon fibers and the natural fibers are wool fibers.
 25. The garment according to claim 24, wherein the rayon fibers are flame retardant rayon fibers.
 26. The garment according to claim 24, wherein the fabric is constructed of yarns formed of about 50 percent flame retardant rayon, about 30 percent wool and about 20 percent nylon fibers.
 27. The garment according to claim 15, wherein the warp knit fabric is a tricot warp knit fabric.
 28. The garment according to claim 15, wherein the fabric has stretch in the width direction of between about 25 percent and 35 percent.
 29. The garment according to claim 15, wherein the fabric has a weight of between about 3.5 oz/yd2 (118 g/m2) and about 4.3 oz/yd2 (146 g/m2).
 30. The garment according to claim 15, wherein the air transmission openings are diamond-shaped in relation to a lengthwise side edge and a widthwise side edge of the fabric. 